Toad

Didn't have as productive a day today, but still got a fair bit done. Used the tractor to hold a wheel still so I could remove the drive shafts from my old subframe. For a car that had FVWSH, I was quite surprised to find 3 CV joints fitted incorrectly... Anyway, will need to buy a new inner joint as it seems to be a bit stuck and no amount of cleaning or fiddling is fixing it. Would be easier to buy Pete_Griffs driveshafts, but I just can't stretch to them. :( Prepped the driveshafts for painting. Fitted the sump gasket after cleaning all the random crap out the sump that fell in during the timing chain and cam swap. Fitted the upper timing chain cover properly, stealing an inlet manifold bolt to do so, refilled the tensioner with oil and nipped that up tight. Fitted flywheel, and bolted gearbox on. Again snuffling a bolt out from my spares pile as I misplaced one... Fitted the new clutch slave cylinder, new cam position sensor and gear selector mech from the old gearbox. Need to replace the gear selector really, but it will do to get the car moving. Cleaned the front engine mount and sprayed with primer. Need to paint it black in the week. Found some nuts and washers out to fit the vibratechnics front mount. Sparayed a bit of filler primer down the side, and more lovely not-quite-the-right-shade-of-white on the boot lid and rear panel. Remembered that the bonnet was still rusty. Swore. Washed the bonnet, and set to work with the grinder, then primed, filled, sanded and finally filler primed the bonnet. Tidied up. Put all the sockets back in sets, and moved the bench so I could drop the engine and box back onto a pallet. Before next weekend, I need to buy a bias valve and inner CV joint, some waxoyl and borrow an applicator gun. I also need to check the subframe mounting points and paint if neccessary. Need to finish the paint round the front end, and have the front subframes and driveshafts ready to fit. Couple of evenings work I suppose. This is a bit rambly now. Sleepytime? Maybe.... Pics...

It is exceptionally rusty. Did anyone ever try snorkling in it? Or water skiing? Goodnight Kirsty....

Hello I'm Badgering a Toad :lol: :lol: I'll get them on the scales tomorrow :)

Me, I won't answer your phone calls asking how to put it together from now on.... Surprising what I can manage in a day. :) Pleased so far.... I'll give you a shout about next weekend on MSN. Little OU day out with Stu and Mic if you fancy it? Plus I could do with pilfering my belt tensioner back :wink:

Today had a bit of a delayed start due to sleeping in a bit and finding out that I needed a smaller torque wrench to do the big end bolts, ours only goes down to 50nm, I needed 30nm, so I didn't really get going till 1pm. Anyway. Found and reinforced a bench to sit the engine on. Filled the box with cheap oil, fitted the clutch release arm, release bearing, and new pivot, and greased everything ready to fit the gearbox. Whipped the sump off the engine, refitted the big end shell on No.6, fitted the oil pump after filling it with oil. sat the sump back on for the time being. Took the rocker cover off and end plates, removed the old timing chains, standard cams, and tappets. Fitted new tappets, schimmel 263 cams and new timing chains, guides etc. Put a new oil seal in the lower cover and glued it back on. Tomorrow I will be sealing the top cover and putting a new rocker cover gasket on, sump gasket, refit the flywheel and bolt the gearbox back on. :) Pics...

It has to be ;) I'm making a big push to get it finished now... It's been far too long. Need to keep making progress now, as I said just now It's been ages in the making. Cheers dude... Not actually doing anything that special, but should have a pretty tidy car to drive at the end. Still keen on adopting it for a week or so? :clap: Can't wait to have you guys down. Cheers dude! Lol. Yeah. That's probably closer to the mark than you realise. Going to have a bleak winter. But at least I will be able to sleep in the car! :)

:) Nomnom.

Put the rear shocks/springs together with some repainted top caps tonight, wire brushed some of the rust off and greased anything up that needed it. Put more paint on the various brackets, and put new seals and bushes in the 288 front calipers, did do a little tiny bit of damage to one of the front seals putting it in :bad-words: But I hope it will be fine. Continued with the painting. Need to find some cheap gearbox oil and fill the box up, fit the new pivot and release bearing arm and get that ready to fit. Then need to do up the con rod bolt, swap the chains, tensioners, tappets and cams, and put the new oil pump in the engine, wack the sump on, and maybe fit the filter housing. Then I can bolt the engine and box up. Need to paint 2 small areas on the block first and get the brackets etc fitted. Also need to clean the PAS lines, and get the subframes ready to be fitted. Plus order a brake bias valve.

Dave showed me a pic of your van with the slogan on the door. Absolutely brilliant :) :lol: :lol: :lol:

Nice work Bethan. :) Interesting to see that overspray on the rad support panel... What was painted before you got your lovely little soft paws on it?

You need the subframes from a 4 cylinder car, and the associated wishbones, rad support panel, slam panel etc. Search for this topic, as there have been several threads on it covering what items are needed etc.

x2 Forgot to say that myself.

:thumbleft: HAMAZING. The innards of gearboxes scare me. Really don't like the idea of digging around inside them.

I concur! I'll try to find some. I should have a couple of good pics of the bad bodywork somewhere... I'll take some this weekend too. :)

Looks nice under the bonnet :) It's not easy keeping up the motivation to get bits finished is it? How's the hernia?

There are a few places that do rebuilds, but getting a good place can be tricky. Try asking DG Autotech, as they have a place around the corner and would be able to do the removal/refitting for you I expect.

I'll weigh them when I am next at home and get a quote. Keep badgering me as I am rubbish at remembering anything!

i should be able to get you some tom, and if i can then they will be cheap too! give me a shout. Cheers Andy... Just put a big parts order in with the garage round the corner so stuck the tappets on with them. Spent a little too much this week... :tongue: I dropped him an email. Fingers crossed. :)

You can fit calipers and carriers from a G60 or VR6 and G60 disks to the front to upgrade the brakes. VW branded disks last well, there are a lot of good pads around, EBC greenstuff, mintex 1144, Ferodo DS2500s, or standard...

You can weasel accounts, but my mate's family own the garage round the corner. :)

If you get stuck I can get you a set, just don't know how to get them to you...

In case anyone is interested, parts are below.... Gearbox seal cover plate end 02A 301 215 A £7.68 Clutch release arm 02J141719B £14.74 Oil pump 021 115 105 B £112.51 Oil filter housing 021 115 433 A £19.90 Rear engine mount 1H0 199 262 K £64.05 Bolt for rear engine mount N 905 532 02 £1.15 Bolt for gearbox mount N 102 416 03 £1.57 Front Disks for mk3 golf VR6 b 3AO 615 301 A x 2 £32 each Seal kit for front brake calipers mk3 golf VR6 b 3A0 698 471 x2 £11.70 each Guide bushes for mk3 golf b 4DO 698 647 x2 £9.38 each Rear Top mounts Upper 191 512 335 x2 £4.16 each Rear Top mounts Lower 191 512 333 x2 £4.16 each Spring base for top mount 1HO 512 149 x2 £2.58 each Splash guard for rear disk left hand. 191 615 611 D £14.18 Splash guard for front disk left 3A0 615 311 £10.95 Spalsh Guard for front disk right 3A0 615 312 £10.95 Bolt for securing splash guard N 905 293 01 x 4 £0.15 Bolt for securing brake caliper carrier to hub N 907 085 02 x 4 £1.71 Inlet manifold to head gasket 021 133 227 H £11.74 inlet manifold to inlet manifold gasket 021 133 227 J £7.49 Flywheel to crankshaft bolts Sump gasket £25ish 2x conrod bearing bolts. £9.04 each... :shock: Set of tappets £80.something Got a discount of between 4% and 10% on the items, so the total was £550ish without the sump and flywheel bolts. Actuall did some work on her tonight. Fitted a set of seals to the front callipers, and did a bit more painting of bodywork and bracketry. Slowly getting there... :)

TPS have them on Parts club prices at £32 each.

Can anyone reccomend a supplier of injector seals? I need to get a set for the VR before I can finish it.

:) No worries. Absolutely love Moonlight blue. Thought about respraying my VR in it for a while. VR i still in progress. Large box of bits waiting for me at home. Going to have a big session on it over the next couple of weeks, and aim to have a running car by the end of August. Got some glamourous helpers coming over soon. :) Didn't make it to Combe, sadly :(